Transfer support and method for fusing a transferrable image to a digital disc

ABSTRACT

A transfer support and a method for fusing a transferable toner image to a face of a digital disc. In the method, a transferable toner image is electrophotographically printed onto a transfer layer. The transfer layer has a surface energy insufficient to retain the transferable toner image against a peel force of greater than about 550 Newtons/meter. The transferable image is registered against the face of the digital disc to provide a transfer support-digital disc pair. The transferable image is fused to the face of the digital disc. Registry of the transferable image and the face of the digital disc is maintained during fusing.

FIELD OF THE INVENTION

The invention relates to methods and apparatus pertaining to digitaldiscs: compact digital discs, photo compact discs, and other similarmedia. The invention more particularly relates to a method for fusing atransferable image to a digital disc and to a transfer support useful inthat method.

BACKGROUND OF THE INVENTION

The term "electrophotographic printer" is used hereafter to refergenerically to electrostatographic copiers and printers, unlessotherwise indicated by context.

The term "digital disc" is used herein to refer generically to anarticle of digital storage media that takes the form of a thin and rigiddisc of unitary structure. A digital disc has a surface, referred toherein as the "face", available for display of printed information.Information stored on a digital disc is generally in optically readableform; however, magnetic storage is not excluded.

Digital discs are finding increasing use in the high density storage ofdigital information, such as digitized music, digitized photographs, andcomputer programs. At present, three principal types of digital discsare in common use. The first type, referred to as a CD or ROM (read onlymemory) disc, is manufactured by pressing depressions into a substrate,in a manner analogous to the manufacture of phonograph records. A secondtype of digital disc, referred to as a writable optical storage disc,has the capability of having information recorded (written) thereon atsome time after fabrication of the medium. A third type, referrred to asan erasable disc, can also have information added after fabrication, butthat information can be erased or modified at a later time.

A digital disc has a substrate overlaid with a layer that stores thedigital information. The substrate is transparent to the radiation usedto read the disc. Overlying the storage layer is a protective layer. Thesurface of the protective layer, also referred to as the "face" or"face", commonly bears printed information. U.S. Pat. No. 5,317,337teaches a method for printing the face of a digital disc using an inkjet printer. Alternative methods or printing, including solid-inkprinting, thermal-transfer technology, dye-diffusion methods, and colorlaser printing are mentioned in relation to an article in the periodical"Computer Design". U.S. Pat. No. 5,282,187 teaches the use of a felt tippen or the like to mark the face of a compact disc.

Digital discs are most often marketed with one or more pieces of humanreadable printed material. For convenience, the term "informationpackage" is used herein to refer to the information included for theuser, in a digital disc of whatever type, along with the informationprinted on the accompanying printed media. Commonly, a digital disc ismarketed in a plastic storage box, commonly referred to as a "jewelbox". A jewel box, typically has a transparent base that includes afolded sheet of informational printed media, referred to herein as a"backplate", covered by an insert (commonly opaque) that grips thedigital disc. A transparent cover is hinged to the base. A booklethaving one or more sheets of folded printed media, referred to herein asan "insert booklet", is commonly held by the cover. U.S. Pat. No.4,709,812 teaches a printed, folded paperboard alternative to a jewelbox.

U.S. Pat. No. 5,163,271, U.S. Pat. No. 5,207,050, and U.S. Pat. No.5,285,620 teach apparatus and methods for assembling digital discs andliterature into jewel boxes or the like.

The above methods have the shortcoming that the printing of a digitaldisc and its accompanying literature are not produced by the sameprinter at the same time. This presents a problem if it is desired tomatch the colors of pictorial copy on both the face of a digital discand on accompanying literature, particularly if it is impractical toproof the color match before a product run. A particular situation inwhich it is impractical to proof colors is the preparation of individualdigital disc information packages on demand.

It would be desirable to provide a method for fusing a transferableimage to a digital disc and a transfer support having a low surfaceenergy transfer layer.

SUMMARY OF THE INVENTION

The invention provides a method for fusing a transferable toner image toa face of a digital disc. In the method, a transferable toner image iselectrophotographically printed onto a transfer layer. The transferlayer has a surface energy insufficient to retain the transferable tonerimage against a peel force of greater than 550 Newtons/meter. Thetransferable image is registered against the face of the digital disc toprovide a transfer support-digital disc pair. The transferable image isfused to the face of the digital disc. Registry of the transferableimage and the face of the digital disc is maintained during fusing.

The invention provides a transfer support having a support layer and atransfer layer overlaying the support layer. The transfer layer has asurface energy insufficient to retain a transferable toner image subjectto a peel force of from 3 to 15 Newtons/meter.

It is an advantageous effect of the invention that a method is providedfor fusing a transferable image to a digital disc and a transfer supportis provided having a low surface energy transfer layer, which method andtransfer support can be used to produce digital discs having goodquality fused toner images.

BRIEF DESCRIPTION OF THE FIGURES

The invention itself will be better understood by reference to thefollowing description of an embodiment of the invention taken inconjunction with the accompanying figures wherein:

FIG. 1 is a diagrammatical view of an embodiment of the method of theinvention.

FIG. 2 is a top plan view of an embodiment of a lamination jacket usefulin the method of the invention. The lamination jacket is shown in anopen configuration. The hinge is indicated by dashed lines.

FIG. 3a is a top plan view of the lamination jacket of FIG. 2 in aclosed configuration and filled with a transfer support and digitaldisc.

FIG. 3b is the same view as in FIG. 3a, except that the shell of thelamination jacket is removed.

FIG. 4 is a cross-sectional view of the filled jacket of FIG. 3 takensubstantially along line 4--4.

FIG. 5 is a detailed diagrammatical view of step D of the method of FIG.1.

FIGS. 6a-6d are semi-diagrammatical views of the fusing procedure of themethod of FIG. 1.

FIG. 7 is a top plan view of another lamination jacket.

FIG. 8 is a top plan view of yet another lamination jacket.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, in step A, a transfer support 10 is first printedwith a toner image using a conventional electrophotographic printer 12.The transfer support 10 has a transfer surface or transfer layer 14 of amaterial that is capable of bearing what is referred to herein as a"transferable toner image" or "transferable image". The transferableimage is identified by the reference numeral 16. A transferable image 16is characterized as being "unfused". The term "unfused" is slightmisnomer. In an electrophotographic printer 12, a toner image isinitially formed of discrete particles of toner which are then fused toeach other and to a receiver. In the method of the invention, tonerparticles on the transfer layer 14 are fused to each other to form the"transferable toner image". There is sufficient adherence of thetransferable toner image 16 to the transfer layer 14 so as to preventsignificant offset, that is, retention of a portion of toner image onthe fusing system of the printer 12. The transferable toner image 16 isnot so adhered to the transfer layer 14 that it will not transfer to adigital disc 18 placed in contact with the transferable toner image 16under conditions substantially the same as those in the fusing system ofthe electrophotographic printer 12. The transfer layer, and transfersupport, also suffer no substantial loss in physical integrity underthose fusing conditions, that is, the transfer layer does not melt,shrink, laminate to the digital disc, or otherwise deleteriously alterwhen the transferable toner image is formed nor when the transferabletoner image is fused to the digital disc.

The transfer layer 14 of the transfer support 10 is a low surface energymaterial that has an adhesive strength, relative to the transferabletoner image, that is within a selected range that allows the transfersupport to retain and then release the transferable toner image asrequired by the method of the invention. This adhesive strength isexpressed herein as a peel force, (peel forces herein are measured at90°). The transfer support has a surface energy that is insufficient toretain a transferable toner image subject to a peel force of greaterthan Newtons/meter. In a preferred embodiment of the invention, thetransfer support has a surface energy that is insufficient to retain atransferable toner image subject to a peel force of from 3 to 15Newtons/meter. The transfer surface 14 is preferably substantially freeof "bare spots" or other artifacts which would adversely effect theimages.

In particular embodiments of the invention, the low surface energymaterial of the transfer layer is selected from the group consisting ofalkyl fluorophosphonates and amorphous perfluorocarbons. In someembodiments, the invention is directed to the transfer of a toner imagefrom such a transfer support to an article, such as a digital disc orother digital media.

In a particular embodiment of the invention, the low surface energymaterial of the transfer layer is an alkyl fluorophosphonate having thegeneral structure: ##STR1## where j is 1 or 2; m is from 3 to 8; n isfrom 1 to 6; and R is selected from the group consisting of NH₄ and H.One example of a commercially available alkyl fluorophosphonate isidentified by the general structure: ##STR2## where m is from 3 to 8.This material is available from E.I. du Pont de Nemours and Co. ofWilmington, Del., under the designation: "Zonyl™FSE". Zonyl™FSE has asurface energy of from 16 to 20 dynes/cm. Another commercially availablealkyl fluorophosphonate is identified by the general structure: ##STR3##where m is from 3 to 8 and j is 1 or 2. This material is available fromE.I. du Pont de Nemours and Co. under the designation: "Zonyl™UR".Zonyl™UR has a surface energy of from 16 to 20 dynes/cm.

In another particular embodiment of the invention, the low surfaceenergy layer material of the transfer layer is an amorphousperfluorocarbon having the general structure: ##STR4## where Rrepresents the atoms and electrons necessary to complete a perfluororing having a total of 5 carbons and heteroatoms, and d and e are molefractions having a sum of 1. Some specific examples of a commerciallyavailable amorphous perfluorocarbons are identified by the generalstructure: ##STR5## where a and b are mole fractions having the sumof 1. An amorphous perfluorocarbon having this structure where a=0.65and b=0.35 is available from E.I. du Pont de Nemours and Co under thedesignation: "Teflon™AF 1600". Another amorphous perfluorocarbon havingthis structure where a=80 and b=20 is available from E.I. du Pont deNemours and Co under the designation: "Teflon™AF 2400". Teflon™AF 1600and Teflon™AF 2400 are aqueous or non-aqueous copolymerization productsof tetrafluoroethene and2,2-bis(trifluoromethyl)-4,5-difluoro-1,3-dioxolane. The glasstransition temperature (T_(g)) of Teflon™AF materials is a function ofthe relative mole fractions of a and b. Teflon™AF 1600 has a T_(g) of160° C. Teflon™AF 2400 has a T_(g) of 240° C. Suitable T_(g) 's for thematerial of the transfer surface 14 are in the range of about 35° C. toabout 300° C.

The transfer support 10 can have a uniform composition such that thetransfer layer is a portion of a unitary structure; but, preferably, thetransfer support 10 has a discrete transfer layer 14 adhered to asupport layer. The support layer acts as a backing for the transferlayer. The transfer layer and transfer support 10 are not limited to anyparticular configurations, however, it is preferred that the transfersupport 10 take the form of a discrete sheet. The transfer support 10can be part of a larger structure, such that the transfer layer coversonly a portion of the support. It is preferred that the transfer layer14 be inset from the margins used by paper handling devices and thelike. Paper handling devices typically require frictional contact withone or more sheet margins and are likely to be adversely effected by thepresence of low surface energy material. The transfer layer can belocated on the support layer so as to meet the requirements of aparticular paper handling device; however, for general purpose use, itis convenient to inset the transfer layer from all sheet margins. Aconvenient inset distance is about one-half inch.

The transfer layer is not limited to a particular thickness, however, itis desirable that the transfer layer be thin so as to minimize usage ofthe low surface energy material. Since excessive surface roughness ofthe transfer layer tends to cause areas of the toner image to beretained on the transfer layer after fusing of the transferable tonerimage, the transfer layer should be sufficiently smooth to ensuresubstantially complete transfer of the toner image to the digital disc.For a thin transfer layer, surface roughness reflects the roughness ofthe underlying support layer, thus, a smooth support layer should beused.

A thin, smooth transfer layer can be conveniently provided by gravurecoating or stamp coating a 0.5 to 2.0 micrometer thick layer of the lowsurface energy material onto a sheet of high quality graphic arts paperor laser printer paper. For example, the support layer can be a sheet ofhigh-clay, acid-sized paper having a Sheffield smoothness of from about120±40 to about 160±40. Specific examples of suitable papers are"Spectratech Laser Gloss™" electrophotographic paper, marketed by ScottPaper Company, of Boston, Mass., and "Vintage Velvet™" graphic artspaper, marketed by Potlatch corp., of San Francisco, Calif. The supportlayer is not limited to paper, but can be transparency material or othermaterial suitable for use as an electrophotographic receiver, that isadequately smooth and meets other requirements of a particular use.

The transfer support 10 can be part of a sheet of specialized media,referred to herein as a "partial transfer sheet". A partial transfersheet has a primary layer that is copy paper or transparency material orother material suitable for use as an electrophotographic receiver.Overlaying a portion of the primary layer is a secondary or transferlayer having a low surface energy. The sheet can thus be divided into aliterature portion having only the primary layer and a transfer support10 or transfer support 10 having both primary and secondary layers. Bothportions can be printed simultaneously, yielding an "unfused"transferable image 16 on the transfer support 10 and a "fused",untransferable toner image on the literature portion.

A preferred electrophotographic printer 12 for use in the method of theinvention is a Kodak™ ColorEdge™ Model 1550+, marketed by Eastman KodakCompany of Rochester, N.Y.

The transferable image 16 is printed onto the transfer support 10 in amirror image orientation. The transferable image 16 can include colorpictorial information or other information subject toelectrophotographic printing, such as magnetically readable characters.The transferable image 16 may be opaque or semi-transparent. In thelatter case, it may be desirable to accomodate the color balance of theimage with the coloration of the face of the digital disc 18. Suchadjustments of color balance can be conveniently provided by digitalmanipulation of the image by methods well known to those skilled in theart or, for particular embodiments of the invention, by a methoddisclosed in a U.S. Patent Application, entitled: "COMPOSITE SHEET ANDMETHODS FOR PRINTING DIFFERENTLY-TRANSFORMED IMAGES USING COMPOSITESHEET", filed concurrently herewith, by Eric Zeise (which is herebyincorporated herein by reference). Color balance could also be addressedby the use of white ink or white toner to modify the coloration of allor part of the face of the digital disc.

Image information used by the printer 12 can be supplied in a variety ofways well known to those skilled in the art. Information can be suppliedfrom a hard or floppy disc in a microcomputer. Information can besupplied by a scanner, or the equivalent portion of a copier.Information can be supplied from a remote source via a computerinterface.

Referring again to FIG. 1, step B illustrates the placement of thetransfer support 10 and the face 22 of a digital disc 18 to form atransfer support-digital disc pair 20. The face 22 of the digital disc18 and the transferable toner image 16 are juxtaposed and the transfersupport 10 and digital disc 18 are in registration. The transferableimage 16 is located on the transfer support 10 such that, when thetransfer support 10 and digital disc 18 are in registry, then thetransferable toner image 16 and digital disc 18 will also be registered.

Step C illustrates the placement of the transfer support 10 and digitaldisc 18 within a lamination jacket 24. The lamination jacket 24maintains registration and protects the transfer support-digital discpair 20 during fusing. It should be understood that steps B and C areillustrated as separate procedures in FIG. 1 for the sake of clarity.Steps B and C can be performed as shown in FIG. 1, or in reverse order;but it is generally most convenient to combine steps B and C as a singleprocedure.

Referring to step D of FIG. 1 and to FIG. 5, the filled jacket 26; thatis, the lamination jacket 24, disc 18, and transfer support 10; is thenfed through a fuser 28 and the transferable toner image 16 is fused tothe juxtaposed face 22 of the digital disc 18. Fusing can be provided byheat, or pressure, or a combination of the two. In currently preferredembodiments of the invention, fusing occurs as a result of heating thetransferable toner image 16 and pressing the heated transferable image16 against the face 22 of the digital disc 18. The heat and pressure canbe applied by roller laminating the transferable image 16-digital disc18 pair. The term "roller laminating" and similar terms are used hereinto refer to procedures in which pressure is applied by moving an objectthrough the nip 30 between a pair of rollers or through other structuresthat apply heat and pressure in a similar manner. For example, an objectcan be roller laminated by supporting the object on a flat plate androcking a curved heated platen over the object. As a matter ofconvenience, the term "rollers" is used generally herein to refer toboth actual rollers and other roller lamination components.

Referring now to FIG. 5, it is highly preferred that the fuser 28 becompliant, that is, that the "nip 30" be subject to enlargement by thepassage of the transfer support-digital disc pair 20. A currentlypreferred fuser is shown in FIG. 5. The filled jacket 26 is rollerlaminated by being fed to a pair of feed rollers 32 and then between apair of heated plates 34, and through the nip 30 between a pair ofcompliant fusing rollers 36. In this fuser 28, nip 30 is indirectlyheated. Rollers 36 can also be directly heated by internal heatingelements (not shown) or the like. The lamination jacket 24, as discussedin detail below, not only keeps registration and generally protects thetransfer support 10 and digital disc 18, but also maintain asubstantially uniform pressure on the transfer support-digital disc pair20 during the fusing step. The lamination jacket 24 does so, byenlarging the nip 30, that is, deflecting the compliant fuser 28 outwardfrom the nip 30, before the transfer support-digital disc pair 20 entersand after the transfer support-digital disc pair 20 exits. The resultingconstant nip size, for the transfer support-digital disc pair 20,provides the substantially uniform pressure. The deflection of compliantfusing rollers 36 and enlargement of nip 30 is shown in FIGS. 6a-6d. InFIG. 6a, the filled jacket 26 is fed into the nip 30. In FIG. 6b, theleading drift 64 causes full deflection of nip 30 prior to entry of thetransfer support-digital disc pair 20 into nip 30. In FIG. 6c, thetransfer support-digital disc pair 20 passes through the fully deflectednip 30. In FIG. 6d, the nip 30 is held fully deflected by trailing drift66, until transfer support-digital disc pair 20 has completely exitedthe nip 30.

After fusing, the filled jacket 26 is cooled, indicated diagrammaticallyin FIG. 5 by arrows 101, and is then opened and the fused transfersupport-digital disc pair 20' is removed. The completed labelled digitaldisc 18' is separated from the lamination jacket 24 and used transfersupport 10. The used transfer support 10 and lamination jacket 24 can bediscarded or, if undamaged, can be reused.

Referring now to FIGS. 2-4 and 7-8, the lamination jacket 24 has a shell38 which defines a pocket 40 for closely receiving the transfer support10 and the digital disc 18. The shell 38 has opposed upper and lowerflaps 42,44. The flaps 42,44 have front and rear flap margins 46,48defining an axis of travel (indicated by arrow 50) of the laminationjacket 24 through the fuser 28. The flaps 42,44 are movable relative toeach other between an open or separated configuration 52 in which theflaps 42,44 are spaced apart and a closed or juxtaposed configuration 54in which the flaps 42,44 are overlapped. The flaps 42,44 are preferablyjoined together by a hinge 56.

The pocket 40 has a depth dimension, indicated by arrow 58,substantially perpendicular to the axis of travel and length and widthdimensions substantially aligned with the larger dimensions of the flaps42,44. The pocket 40 can be formed as a result of compliance of theflaps 42,44 about an interleaved transfer support 10 and digital disc18. It is preferred, however, that the pocket 40 defined by the flaps42,44 be further defined by an insert 60 disposed interior to the shell38. The shell 38 and insert 60 can be made from a single unitarystructure; however, the shell 38 and insert 60 can be discretestructures permanently adhered together.

The insert 60 can have a collar 62, a leading drift or leading edgesection 64, a trailing drift or trailing edge section 66. The drifts64,66 are forward and rearward of the collar 62, respectively. Thecollar 62 adjoins the pocket 40 and extends from the leading drift 64 tothe trailing drift 66. The insert 60 can be a unitary structure or cancomprise several pieces. The collar 62 can be deleted such that theinsert 60 consists of leading and trailing drifts 64,66. The insert 60can be limited to a single drift 64 or 66.

The materials used for the lamination jacket 24 must be sufficientlycompliant such that pressure imposed on the shell 38 is substantiallytransferred to the tranfer support-digital disc pair 20. On the otherhand, it is undesirable for the lamination jacket 24, and in particularthe shell 38, to be so limp that the flaps 42,44 readily assume aplurality of closed configurations. It is instead highly preferred thatthe materials used for the lamination jacket 24 are sufficiently stiffthat the hinge 56 biases the flaps 42,44 against assuming configurationsin which the flaps 42,44 are skewed relative to each other.

The shell 38 and insert 60 can be made as a single unitary structure orcan take the form of separate components joined together. The shell 38and insert 60 can also be partially unitary. For example, the insert 60and part of the shell, such as an inner layer, can form a unitarystructure having one or more additional shell layers adhered over theoutside.

The lamination jacket 24 can be made from low cost materials such aspapers and plastic films; however, the lamination jacket 24 must beconfigured to alleviate any undesirable characteristics of materialsused. For example, it is highly desirable that the lamination jacket 24not offset onto the fuser 28 during use and that moisture be excludedfrom the transfer support-digital disc pair 20 during fusing. Someplastics readily offset at fusing temperatures and pressures. Papershave high moisture contents.

An example of a lamination jacket 24 that overcomes these shortcomingsis shown in FIGS. 2-4. The shell 38 has two layers 68,70. A non-offsetlayer 68 of paper is disposed on the outside. A moisture barrier layer70 of plastic film is disposed on the inside between the non-offsetlayer 68 and the insert 60. Suitable materials for the moisture barrierlayer 70 include polyester and polypropylene. The insert 60 is amoderately stiff, heavy stock paper like bristol board. A variety ofother materials could also be used for the layers 68,70, taking intoconsideration the conditions encountered within the nip 30. For example,the glass transition temperature of polymers used should not be belowthe temperatures encountered in the nip.

Referring again to FIGS. 2-4, when the lamination jacket 24 is in closedconfiguration 54, the digital disc 18 contacts the insert 60 only alongthe circumference of the disc 18. The bottom 72 of the disc 18 contactsthe moisture barrier layer 70 of the shell 38. The face 22 of the disc18 contacts the transfer support 10, which also mostly contacts theshell 38 rather than the insert 60. The result is that the moisturebarrier layer 70 substantially moisture-proofs the transferable image 16and digital disc 18 relative to the paper insert 60 during fusing. Thenon-offset layer 68 protects the moisture barrier layer 70 from thefuser 28 so that the shell 38 is substantially free from offset at atemperature and pressure sufficient to fuse the transferable image 16 tothe digital disc 18.

The shell 38 is preferably configured to extend over the entire bottomof the digital disc 18 and the backside of the transfer support 10 tosubstantially isolate the transferable image 16 and digital disc 18 fromthe fuser 28 and protect against scuffing or other mechanical injuryduring transport. Referring now to FIGS. 3a-3b, extreme corners of thelamination jacket 24 can be left as sharp points or can be radiused orthe like, as desired. If the transferable image 16 is rectangular, thenradiused comers can provide a visual reference as to whether a transfersupport 10 has been placed within the lamination jacket 24.

The leading drift 64 adjoins the front flap margin 46. The trailingdrift 66 adjoins the rear flap margin 48. The drifts 64,66 are eachtransverse to the axis of travel 50 and tangential or substantiallytangential to the pocket 40. In the embodiment of the lamination jacket24 of FIGS. 2-4, the drifts 64,66 each have substantially the same widthdimension as the pocket 40 in a direction substantially perpendicular tothe axis of travel 50. Drifts 64,66 having a width-wise extension thatis less than that of the pocket 40 are not considered optimal. Extensionof drifts 64,66 substantially beyond the pocket 40 in the directions ofthe width dimension is not considered critical, but can be provided as amatter of design convenience.

During fusing the drifts 64,66 force resilient expansion of the nip 30forward of the transfer support-digital disc pair 20 and allow resilientcontraction of the nip 30 rearward of the transfer support-digital discpair 20. This provides a substantially uniform area within the nip 30during fusing of the toner image, so as to minimize non-uniformities inthe pressure applied by the compliant rollers to the face 22 of the disc18. When the lamination jacket 24 passes between the compliant rollers36, the nip 30 expands and contracts in spaced relation to the pocket 40and maintains a substantially constant dimension as the pocket 40 passesthrough the nip 30. Non-uniform pressure or areas of excess pressure,are apparently due to less area within the nip 30, and were determinedto be related to localized smearing of the toner image.

It is currently preferred that the drifts 64,66 expand the nip 30 to thesame extent as the transfer support-digital disc pair 20. This can beprovided by a lamination jacket 24, that is made of relativelyincompressible materials and that, at least when filled, has a constantthickness. The lamination jacket 24 of FIGS. 2-4 and 7 meet thisprovision. The drifts 64,66 each have a constant thickness that issubstantially the same as the depth of the pocket 40 and the thicknessof the transfer support-digital disc pair 20. Since the transfer support10 is ordinarily thin, the thickness of the drifts 64,66 is alsosubstantially the same as the thickness of the digital disc 18. Forexample, 0.127 cm (0.050 inches) is a suitable thickness for drifts64,66 for use with a commonly used variety of digital disc 18 having astandarized thickness of 0.127 cm (0.050 inches).

In the embodiment of the lamination jacket of FIGS. 2-4, the collar 62and drifts 64,66 each have an upper subunit 74,76,78, respectively, anda lower subunit 80,82,84, respectively. The upper subunits 74,76,78together define a unitary upper half-insert 86. The lower subunits80,82,84 together define a unitary lower half-insert 88. The twohalf-inserts 86,88 together have substantially the same thickness as thedigital disc 18, that is, a thickness that is substantially equal to thedepth of the pocket 40. The upper half-insert 86 is joined to the upperflap 42. The lower half-insert 88 is joined to the lower flap 44. Thehalf-inserts 86,88 are displaceable relative to each other between aopen or spaced apart configuration and a closed or juxtaposedconfiguration. The half-inserts 86,88 each have a cut-out 90. Thecut-outs 90 have outer ends occluded by the shell 38 and inner endssubstantially aliged when the half-inserts 86,88 are in the closedconformation. The cut-outs 90 together define continuous lateralboundaries for pocket 40, which is shaped like a short cylinder having adiameter only slightly larger than the diameter of the digital disc 18and a depth that is substantially equal to the thickness of the digitaldisc 18. It is convenient if each half-insert 86,88 has a uniformthickness equal to about half the thickness of the digital disc 18.

The lamination jacket 24 includes transfer support and digital discguides 96,98 for registering the transfer support 10 and digital disc 18within the pocket 40. The transfer support 10 and digital disc 18 areboth registered relative to the lamination jacket 24, and thusregistered relative to each other. With the lamination jacket 24 in theopen configuration 52, the guides 96,98 aid in the placement of thetransfer support 10 and digital disc 18 within the lamination jacket 24,by inhibiting lateral movement once the digital disc 18 or transfersupport 10 has attained a registration position. With the laminationjacket 24 in closed configuration 54, the guides 96,98 help inhibitrelative movement of the transfer support 10 and digital disc 18 duringfusing. The guides 96,98 adjoin one or both flaps 42,44.

The guides 96,98 can provide registration in one or two dimensions.Movement of the transfer support-digital disc pair 20 in a firstdimension parallel to the central axis 100 of the digital disc 18 isconstrained by the overall configuration of the lamination jacket 24 andby the fuser 28. The guides 96,98 constrain movement in one or both ofthe the two dimensions, referred to herein as "length" and "width",perpendicular to the central axis 100 of the digital disc 18. It ispreferred that guides 96,98 constrain movement of the transfer support10 and digital disc 18 in length and width dimensions.

FIG. 8 illustrates a lamination jacket 24 having guides 96,98 thatprovide registration in one dimension. The tranfer support and digitaldisc guides 96,98 are adjoining portions of the inner surface 22 of thehinge 56. The transfer support 10 and digital disc 18 both can beabutted against the hinge 56 to provide registration in a directionparallel to the length dimension of the lamination jacket 24.Registration parallel to the width dimension of the lamination jacket 24is provided manually and is maintained by frictional resistance of thelamination jacket 24.

A convenient configuration for the digital disc guide 98 that provideslength and width registration is a continuous or discontinuous ring thatclosely fits with a complementary structure on the digital disc 18. Ifthe ring is discontinuous, it preferably has three or more contactpoints spaced to limit disc movement in length and width dimensions. Thedigital disc guide 98 can closely fit the outer edge of the digital disc18 or a complementary structure on the digital disc 18, for example, anannular indentation near the inner margin. In the lamaination jacketshown in FIGS. 2-4, the digital disc guide 98 is a portion of the rim ofthe pocket 40.

The configuration of the transfer support guide 96 depends upon theconfiguration of the transfer support 10. For example, if the transfersupport 10 is circular in outline and about the same diameter as thedigital disc 18, then the transfer support guide 96 is a portion of therim of the pocket 40. If the transfer support 10 is rectangular orsquare in outline, then the transfer support guide 96 can beappropriately located tabs or edges protruding from the insert 60 orshell 38. The lamination jacket 24 shown in FIGS. 2-4, can utilize bothdisc-shaped and rectangular transfer supports. The rim of cut-outs 90has an upper portion that defines guide 96a, which can engagedisc-shaped transfer supports, and a lower portion that defines guide98, which can engage discs.

FIG. 7 illustrates a lamination jacket 24 in which the transfer supportguide 96 consists of the inner edges of drifts 64,66. Registration isprovided by the guide 96 only in the length dimension. Registration inthe width dimension is provided manually. The digital disc guide 98 hasthe form of a raised annulus extending inward into pocket 40 from layer70 of shell 38, that mates with a complementary indentation in digitaldisc 18 and provides registration in length and width dimensions.

Tolerances for the guides 96,98 are determined by acceptable tolerancesfor the position of the image on the completed disc. Ordinarily rotationof the position of the transferable image 16 about the axis 100 of thedisc 18 is inconsequential. Thus the primary tolerance at issue forlocating the transferable image 16 on the digital disc 18 is the radialoffset of the center of the image from the axis 100 of the digital disc18. An example of a suitable tolerance is 1 millimeter in radial offset

With transfer supports 10 having a circular or other radiallysymmetrical outline, alignment of the transfer support 10 and digitaldisc 18 about a common center can be easily established solely by use ofappropriately sized guides. With rectangular transfer supports ortransfer supports having a non-centered transferable image or the like,it may be convenient to provide one or more visible indicators (notshown) as registration aids on the transfer support 10, and, if desired,on the lamination jacket 24. For example, the transfer support 10 andlamination jacket 24 can include matching arrows or other visibleindicators to aid an operator in properly orienting the transfer support10 relative to the lamination jacket 24. A visible indicator can belocated in a "waste" section of the transfer support 10.

In use, referring to FIGS. 2-4, the lamination jacket 24 is opened, adigital disc 18 is placed in one of the cut-outs 90, a circular transfersupport 10 is placed in the other cut-out 90, and the jacket is closedto superimpose the two cut-outs 90. After fusing and cooling, thelamination jacket 24 is opened. The transfer suport-digital disc pair 20is removed from the lamination jacket 24. The transfer support 10 isstripped off, resulting in the completed digital disc 18' bearing afused toner image (not indicated in figure). The completed digital disc18' is then assembled with any accompanying literature and packaging(not shown). Post-fusing steps can be performed manually or by automatedequipment comparable to that currently used in production of packageddigital discs.

The following Examples and Comparative Examples are presented to furtherillustrate some preferred modes of practice of the method of theinvention. Unless otherwise indicated, all starting materials werecommercially obtained.

EXAMPLES 1-8

Transfer supports were prepared by gravure coating using the low surfaceenergy materials, coating thicknesses and support layers indicated inTable 1. (Under "Support layer", "laser printer" represents SpectratechLaser Gloss™ electrophotographic paper and "graphic art" representsVintage Velvet™ graphic art paper.)

Full color images were photocopied onto the transfer supports using aColor-Edge™ 1550 Copier Printer, marketed by Eastman Kodak Company ofRochester, N.Y.

The peel force values in the table represent tested values for minimumpeel force required to remove toner from a transfer layer. Peel force isa measure of the adhesive strength of the bond between the transferabletoner image and the transfer support. Peel force was measured bypressing each of a series of standarized tapes to a solid colortransferable toner image on a respective transfer support. The length ofeach tape was attached to a respective transfer support. A free end ofthe tape was then pulled outward at an angle of 90° relative to thetransfer support until the tape was withdrawn. The tape was thenexamined for the presence of toner. The tapes were standardized bydirectly measuring peel force required to peel a respective tape from apoly ethylene terephthalate substrate at 90 degrees. The tapes wereutilized beginning with lowest values of peel force and testing wascontinued for each transfer support until toner was removed.

Waste areas were then cut away from the printed transfer supports,resulting in printed and configured transfer supports having a circularoutline and about the same circumference as a digital disc.

Transferable toner images on the transfer supports were then fused toindividual digital discs. The digital discs used were Photo-CD™ discsmarketed by Eastman Kodak Company of Rochester, N.Y.

A lamination jacket was used during fusing. The jacket had a shellhaving an inner layer of 0.0508-0.0762 millimeter (0.002-0.003 inch)thick Mylar film and an outer layer was 0.0762-0.127 millimeters(0.003-0.005 inches) thick paper. The multilayer shell when opened wasabout 31.8 cm (12.5 inches) by 12.7 cm (5 inches). Comers were radiusedin about 0.64 cm (0.25 inch). A insert of 0.635 millimeters (0.025inches) cardboard was adhered to the inside surface (the Mylar surface)of the multilayer shell. The insert was comprised of two halves, eachabout 12.7 cm (5 inches) by about 15.2 cm (6 inches); joined by a foldedpaper hinge. Each half-insert had a circular central cut-out about 12.1cm (4.75 inches) in diameter.

The jacket was opened and a digital disc was placed inside one of thecut-outs using the rim of the cut-out as a guide. A transfer support wasthen placed over the digital disc with the edge of the transfer supporttouching the hinge and was then further aligned visually with thedigital disc and the edges of the jacket. The resulting jacket, digitaldisc, and transferable image, referred to collectively herein as a"filled jacket", was then roller laminated using a Model No. 6000laminator from Laminating Arts of New York Inc. This device has a set offeed rollers having a diameter of 19.05 millimeters (0.75 inches) and aset of similarly sized pressure rollers. A pair of heater plates adjointhe path between the pressure and feed rollers. The laminator provides afusing pressure of 2.89-5.79 kg/cm² (50-100 pounds per square inch). Thetemperature and speed controls were modified so as to expose the filledjacket to a temperature of 350° C. at a speed of 11.43 millimeters persecond (0.45 inches per second).

After lamination, the filled jacket was cooled and the transfer supportwas separated from the fused image.

In all of the Examples, the transfer support removed easily and wascompletely clean or exhibited only a slight residue of toner: and thefused image on the digital disc was free of smearing or otherdistortion.

COMPARATIVE EXAMPLES 1-4

The procedures of Examples 1-8 were substantially repeating using thetransfer supports indicated in Table 1. In each of the ComparativeExamples, the transfer support fused to the digital disc and could notbe removed.

                  TABLE 1                                                         ______________________________________                                                                      Transfer layer                                                                         Peel                                   Ex or              Transfer layer                                                                           thickness                                                                              force                                  Comp Ex Support layer                                                                            material   (microns)                                                                              (N/m)                                  ______________________________________                                        Ex 1    laser printer                                                                            Zonyl ™ UR                                                                             0.75    5-15                                   Ex 2    laser printer                                                                            Zonyl ™ UR                                                                             1.25    5-15                                   Ex 3    laser printer                                                                            Zonyl ™ FSE                                                                           0.5      5-15                                   Ex 4    laser printer                                                                            Zonyl ™ FSE                                                                           1.0      5-15                                   Ex 5    graphic art                                                                              Zonyl ™ UR                                                                            0.5      5-15                                   Ex 6    graphic art                                                                              Zonyl ™ UR                                                                            0.5      5-15                                   Ex 7    laser printer                                                                            Teflon ™ AF                                                                           0.5      3-10                                                      2400                                                       Ex 8    laser printer                                                                            Teflon ™ AF                                                                           0.5      3-10                                                      1600                                                       Comp Ex 1                                                                             laser printer                                                                            Zonyl ™ FSN-                                                                          0.5      >550                                                      100                                                        Comp Ex 2                                                                             laser printer                                                                            Zonyl ™ FSO-                                                                          0.5      >550                                                      100                                                        Comp Ex 3                                                                             laser printer                                                                            none       --       >550                                   Comp Ex 4                                                                             graphic art                                                                              none       --       >550                                   ______________________________________                                    

Digital disc list

transfer support 10

electrophotographic printer 12

transfer layer 14

transferable image 16

digital disc 18

face 22

transfer support-digital disc pair 20

lamination jacket 24

fuser 28

filled jacket 26

heated plates 34

fusing rollers 36

nip 30

drift 64

shell 38

pocket 40

flaps 42, 44, 46, 48

arrow 50

configuration 52

hinge 56

insert 60

collar 62

drift 64, 66

layers 68,70

configuration 54

bottom 72

axis of travel 50

upper subunit 74,76,78

lower subunit 80, 82, 84

upper half-insert 86

lower half-insert 88

cut-out 90

We claim:
 1. A transfer support comprising a support layer and atransfer layer overlaying the support layer, the transfer layer having asurface energy insufficient to retain a transferable toner image subjectto a peel force of from about 3 to about 15 Newtons/meter.
 2. Thetransfer support of claim 1 wherein the support layer is anelectrophotographic receiver sheet having a central portion and aplurality of margins, and the transfer layer is inset from at least onethe margin.
 3. A transfer support comprising a support layer and atransfer layer overlaying the support layer, the transfer layercomprising a material selected from the group consisting of: alkylfluorophosphonates and amorphous perfluorocarbons.
 4. The transfersupport of claim 3 wherein the alkyl fluorophosphonates and amorphousperfluorocarbons have surface energies of less than about 25dynes/centimeter.
 5. The transfer support of claim 3 wherein thematerial is alkyl fluorophosphonate having the general structure:##STR6## wherein j is 1 or 2;m is from about 3 to about 8; n is fromabout 1 to about 6; R is selected from the group consisting of NH₄ andH.
 6. The transfer support of claim 5 wherein j is 1 and R is NH₄.